Page C, Const. Photos 1/2

Photo 2 - Template cut from drawing Sheet 9, plastic-laminated front and back.
The template is approx. 4-3/4" wide x 14-1/4" long.

Photo 3 - Template glued on a 5" wide x 14-1/2" plywood base.
The base can be 1/4", 3/8", or 1/2" thick.

Skip The Template ?? . . NO! You might be tempted to skip putting the template on the wood, as shown in Photo 3, and save some time by just putting the parts directly on the wood, without using the template. I would CAUTION you NOT to skip the template. If you do skip it, you will save a few minutes of construction time, but you will REGRET it for the rest of the time that you use this unit. I know this, because I built my early pre-1994 units without templates, and I am always having to SEARCH for drawings to see how something on them connects. With the template, you have all the "hook up" information you need, right on the control unit.

 

Photo 4 - You can use the drawing in Sheet 9 Fig. 9.2 as a template
to punch hole centers in the side of the rheostat bracket.
The paper template can be glued to the metal using rubber cement or a glue stick.

Photo 5 - You can use the drawing in Sheet 9 Fig. 9.3 as a template
to punch hole centers in bottom of rheostat bracket.

About The Angle The piece of angle you see in the above two photos, measures about 1/2 wide on the bottom side, and about 1-3/4" on the vertical side. I found it in the home of my now-deceased parents, and I CANNOT FIND where to get more of it. You can use the 1-1/2" x 1-1/2" x 1/8" thick aluminum angle that you can find in the home stores. Ideally you would like to cut the bottom side from 1-1/2" down to about 1/2", so it fits in the available space, and does not cover the wires on the template.

 

Photo 6 - Rheostat bracket attached to base.

Photo 7 - Base with all parts attached, ready to begin wiring.
(The black LED was later removed and not wired for this unit.)

About Wire Gauges The parts list Sheets 7 & 8 call for 18 gauge wires. The red, yellow, & green wires can be smaller, since they carry a small amount of AC current. But the blue & black wires should be 18 gauge minimum, since they carry the DC track current. About Wire Assembly Order Connect black & blue (DC) wires first. Connect red, yellow, & green (AC) wires 2nd. Connect any red, yellow, green & blue wires that connect to parts on the rheostat bracket LAST. (If you connect these first, then you have to "fish" the other wires underneath, which is cumbersome.)

 

Photo 8 - Control Unit with all wires attached.

Photo 9 - Control Unit viewed from the other side